Process for molding cloth including a fabric layer, the stitches thereof having never been thermally set and molding a cloth-covered foam filled product

ABSTRACT

A method of molding cloth. A special multi-layer cloth is drawn into a mold by means of a vacuum between the cloth and the mold. The cloth includes a fabric layer, stitches of the fabric having never been thermally set, a polyurethane foam layer and a polyvinyl chloride film layer bonded together. After the cloth has conformed to the contours of the mold, the shape of the cloth is fixed to maintain the mold contours. To this end, the cloth may be heated, or polyurethane foam may be poured into the mold and allowed to expand.

BACKGROUND OF THE INVENTION

This invention relates to a method of molding cloth, and moreparticularly, to a method of molding a multi-layer, vacuum-formablecloth which may be employed as the outer covering of seat cushions,acoustical dividers and the like.

The traditional method of making upholstered seat cushions involves: (1)cutting the cover material according to an appropriate pattern; (2)sewing the cut material; and (3) stuffing the cushion. High labor costsresult, since, in many situations, the cutting and sewing operations areextensive and much must be performed by hand.

To reduce the cost of manufacturing seat cushions, a molding process wasdevised for manufacturing seat cushions comprising a foam portion havingan integral vinyl cover. The vinyl covering is first heated and thendrawn into a cold mold by means of a vacuum between the vinyl and themold. As the vinyl cools, it assumes the contours of the mold. Foam isthen poured into the mold to form the integral foam portion of the seatcushion. This process significantly reduces manufacturing costs andresults in a superior seat.

However, cloth has many advantages over vinyl. Specifically, cloth iswater vapor permeable. Perspiration that normally collects behind aperson sitting in a vinyl seat can pass through cloth and be evaporatedso that cloth feels cooler during warm weather and warmer during coldweather. Furthermore, the feel of the cloth, the "hand", is much moreluxurious and elegant.

To reduce the expense of cloth covered seats, attempts have been made todevelop cloth molding processes similar to that described above withrespect to vinyl. U.S. Pat. No. 3,954,537 to Alfter et al discloses aprocess for producing multi-layer sheets having a polyurethane foamlayer bonded to a cross-linked polyethylene foam layer. Alfter disclosesthat it is particularly advantageous to join the foam layers withfurther layers such as fabric to form upholstery components. Alfterrelies on the strength of the bond between the polyurethane foam andpolyethylene foam to accomplish the molding. However, polyurethane foamin an uncured state can easily change shape. Since Alfter relies on thebonding of two foam layers, and not on the setting in some manner of theouter fabric layer, intricate detail is most likely not possible, andsince polyurethane foam in an uncured state can change shape easily, itappears likely that the fabric layer would tend to return to its flatshape.

German Offenlegungsschrift No. 2,227,143 to Bayer AG, discloses a seatcushion with a textile cover and a foam core. A fabric is bonded to apolyether-urethane foam layer which in turn is bonded to a film sealinglayer. This multi-layer fabric is first heated to 70° C. (158° F.) andthen drawn into a mold. A soft foam is then poured into the mold to forma seat cushion.

The following patents describe methods of forming a multi-layer clothsimilar to that described above:

U.S. Pat. No. 3,941,633-Wang et al (1976)

U.S. Pat. No. 3,933,548-Anderson et al (1976)

U.S. Pat. No. 3,748,217-May et al (1973)

British Pat. No. 1,227,760-Dunlop (1971).

Although the cloth molding processes described in Bayer and Alfter dowork with some molds and fabrics, the applications are rather limited.For example, the Bayer Patent recites that only elastic knit fabrics maybe employed. The complexity of the mold pattern is also significantlylimited. The molded fabric will not retain the contours of moreintricate or sharp mold features.

SUMMARY OF THE INVENTION

The nearly universal method of making fabric induces characteristics inthe fabric which tend to work against a cloth molding process. After afabric is knitted or woven, the fabric may then be bleached and eitherpiece dyed or printed (provided the yarn forming the fabric had not beendyed). After dyeing (or after knitting or weaving, if yarn dyeing wasemployed) the fabric is subjected to any one of a number of processeswhich are collectively called finishing.

One of the most common finishing processes is tentering which sets thedimensions of a piece of fabric after knitting or weaving and dyeing. Atentering machine stretches the preferably wet fabric to shape as thefabric is passed over a source of heat. The heat serves to set thefabric stitch so that the fabric maintains the desired dimensions afterremoval from the tentering machine.

During the calendering process, another commonly employed finishingstep, fabric passes between a series of heavy, heated, steel rollers atpressures up to 2000 lbs. per square inch. Not only does the calenderingprocess give the fabric a smooth and even luster, but also, the processsets the stitch of the material.

Modern high-speed production, not natural processes, cause shrinkage incotton, nylon, rayon, and wool. The whole process of manufacture, fromfiber procurement or creation, to final calendering subjects the fibersto constant stretching. To control shrinkage typically, a sample ofmaterial is washed and the shrinkage is measured. The degree ofshrinkage of the sample piece is used to determine the degree to whichlarger pieces will shrink. The larger pieces are then mechanicallycompressed back to the dimensions it would have had if it had not beenstretched during manufacturing. To accomplish this, the damp pieces areplaced in firm contact with an elastomeric layer which is stretched overa roller. When the layer is allowed to contract, the cloth contractswith it. The stitch of the fabric is then heat set to the smallerdimensions.

Thus in many of the most common finishing steps the stitch of the fabricis heat set. These finishing processes are so common that it isdifficult to obtain fabric, particularly synthetics, wherein the stitchhas not been set.

In fact, even some dyeing processes set the fabric stitch by subjectingthe fabric to heat while under tension. Typical piece dyeing involvesforming a rope with the piece of fabric. The rope is then circulatedthrough a dye bath and a dryer under tension. This tends to set thefabric stitch.

When the fabric stitch is heat set, the elasticity of the fabric issignificantly reduced. Upholsterers in the past have found thischaracteristic particularly advantageous. A sewn cushion will become"baggy" with use if the fabric of the cover is too elastic. Heat settingsolves the bagging problem.

However, if the fabric elasticity is reduced the fabric will not bedrawn into more intricate mold patterns and will not retain its shape.The Bayer disclosure teaches the necessity of employing an elasticfabric in an attempt to overcome this problem.

Almost any fabric has sufficient elasticity to be employed in the clothmolding process of the present invention, prior to finishing processeswhich set the fabric stitch. Furthermore, once the stitch of the fabricis set, it is rather difficult to recover the elasticity that the fabricoriginally had.

Almost any cloth having a fabric layer which has not been heat set,bonded to an elastic, preferably thermoplastic, composition layer, mayreadily be molded by the present invention. The cloth is drawn into themold by a vacuum between the cloth and the mold. The other portion ofthe mold is positioned and the poured-in-place foam is permitted toexpand. The cloth may be held in the mold shape by the foam core or anyother method well known in the prior art, or by heating the cloth to thefabric stitch set temperature as in the preferred embodiment herein andin U.S. application Ser. No. 22,592 to I. Weir Sears et al entitledPROCESS FOR MOLDING CLOTH IN A HOT MOLD, filed concurrently and assignedcommonly herewith and U.S. application Ser. No. 16,172 to Quertainentitled MOLDABLE CLOTH PRODUCT AND METHOD OF MAKING SAME, filed Feb.28, 1979 and assigned commonly herewith. The contents of both of theseapplications are incorporated herein by reference. A finished seatcushion is then extracted from the mold.

Since the fabric stitch has not been previously heat set, the fabric isable to stretch sufficiently to conform to intricate mold patterns.

The use of cloth, and particularly the cloth molding process of thepresent invention, results in numerous advantages. Cushion shapes thathad heretofore been impossible, particularly in sewn construction, areeasily obtained by the process of the present invention. The possibleshapes include complex curves, concave and convex portions, tufts, andthe simulation of tufting buttons. Many of these shapes have not evenbeen possible with previous cloth molding processes.

Labor savings are achieved with the cloth molding process of the presentinvention, because the cloth is processed and shaped much more quicklythan in the traditional cutting and sewing process. Shapes commonlyfound in tufted furniture require yards of sewing. The assembly of tuftsand tufting buttons also require extensive labor. With the presentinvention, they can be vacuum formed instantaneously, complete withsimulated tufting buttons and poured-in-place foam.

The present invention makes possible the exact duplication of shapes.The inaccuracies of sews construction are eliminated.

The integrity of the cloth is improved by this process since the clothis held in place by a sandwich construction, thus eliminating thecreasing or puckering of material which occurs in upholstered furnitureafter use.

The durability of the resulting cushion is improved because the clothcomposite and the polyurethane poured-in-place foam act as a unit. Thisimproves the life of the cover, because it flexes with the foam ratherthan independent of it.

The present invention may be employed to mold cloth for any conceivableapplication. Such applications include automotive vehicle seats,aviation seats, and dental chair cushions, drafting stool cushions,other seating applications; padding for headboards, baby carriages, barfronts, church kneelers, boots, school buses, and hand rails; andpaneling and wall coverings for elevators, offices, tables, and kitchencabinets.

BRIEF DESCRIPTION OF THE DRAWING

These and other objects and advantages of the invention will become moreapparent and more readily appreciated from the following detaileddescription of the presently preferred exemplary embodiment of theinvention taken in conjunction with the accompanying drawing, of which:

FIG. 1 is a cross section of the product of the present invention;

FIG. 2 is an illustration of the preheating step of the presentinvention;

FIG. 3 is an illustration of the cloth insertion step of the presentinvention;

FIG. 4 is an illustration of the heating step of the present invention;

FIG. 5 is an illustration of the foam pouring step of the presentinvention;

FIG. 6 is an illustration of the curing step of the present invention;

FIG. 7 is an illustration of the cushion extraction step of the presentinvention; and

FIG. 8 is an illustration of the resulting product of the presentinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENT I. The Cloth

An important aspect of the present invention is the particular type ofcloth which is employed. Referring now to FIG. 1, cloth 10 includesfabric layer 12 bonded to elastic composition layer 14. Fabric layer 12is the exterior, decorative layer which enhances the appearance of theproduct resulting from the present invention. Also, the use of fabricenhances the thermal comfort of the product due to the air-flow throughthe fabric.

A. Fabric Layer

Fabric layer 12 may be either knitted or woven. Knitted fabrics may beeither warp knit or circular knit, single knit or double knit. Nearlyany natural, artificial or synthetic material may be employed such aswool, cotton, polyamide, polyester, vinyl chloride, vinyl chlorideacrylonitrile (modacrylic) or polyacryl fibers.

Molding intricate patterns is more easily accomplished with fabricshaving greater stretch. Therefore, the process is more easily performedwith knitted materials than woven materials since knitting produces amore elastic fabric than weaving. Polyamide, such as type 6 and type6.6, polyester, vinyl chloride, vinyl chloride acrylonitrile copolymers,elastomer urethane and polyacryl fibers are preferable materials forweaving due to their inherent elasticity. Furthermore, the use as aground yarn of the fabric of any of the texturized polyamide orpolyester high elasticity yarns, or very high thermoplastic yarns likevinyl chloride and vinyl chloride acrylonitrile aids the moldingprocess.

Some fabrics are more easily heat set than others. For example,polyamide, polyester, vinyl chloride, vinyl chloride acrylonitrile aremore easily heat set than cotton and wool.

To maintain the maximum amount of elasticity in a fabric, the fabricstitch must never have been thermally set. Many of the fabric finishingsteps, such as tentering, calendering and shrinkage control heat thefabric, thus setting the stitch. The concept of setting the stitch iswell known in the art and is easily measured by comparing the degree ofelasticity of a fabric immediately after weaving or knitting, and againafter finishing. If the fabric has become heat set during the finishingprocess, the elasticity is greatly reduced. Clearly, employing heat todry a fabric (as occurs in the tentering, calendering and shrinkagecontrol processes) sets the fabric stitch. Tensioning the fabric whileit is heated increases the degree to which the stitch is set.

In addition to many of the fabric finishing steps, some dyeing processesmust be avoided. In many dyeing procedures the cloth is sewn into a ropeand processed under tension. It is common to heat the dye bath toapproximately the boiling point of water. The material is then dried ata raised temperature. This may heat set the fabric stitch. It has beenfound that yarn dyeing avoids this problem since the weaving or knittingprocess creates elasticity in the fabric. It appears that the realproblem to be avoided is setting the stitch of the fabric rather thanheat setting, in some manner, the yarns from which the fabric iscreated.

The temperature to which a fabric may be heated before the stitchbecomes set varies with the type of fabric. For example, the stitch of apolyamide fabric may become set at a temperature of 93° C. (200° F.).

B. Foam Layer

In the preferred embodiment, elastic composition layer 14 includes foamlayer 16 and film layer 18. Foam layer 16 must have good adhesion toboth fabric 12 and film 18. Foam layer 16 is preferably any typical openmicrocell soft foam. The preferred embodiment employs polyester-typepolyurethane foam, although other foams are suitable, such aspolyester-polyether-type polyurethane. An advantage of polyester-typepolyurethane foam over polyether-type polyurethane is that it has abetter "memory". Polyester-type foam tends to retain the shape in whichit was molded better than polyether-type polyurethane foam.

Foam layer 16 allows movement of fabric 12 relative to film 18 andprevents the rupture of film 18 that might result from elongation ofcloth 10 if fabric 12 were directly attached to film 18. Obviously, ifan alternative method is employed to prevent rupturing, foam layer 16would not be necessary.

Foam layer 16 also improves the "hand" or feel of cloth 10. Since foam16 is preferably open celled, air may circulate through the foam thusimproving the thermal comfort of the seat. Neoprene foam may also beused; however, it is less desirable since it is a closed cell foam.

In the preferred embodiment, foam 16 is 1.5-6 millimeters (mm) thick andhas a density of 30-60 Kg/m³. Also, foam 16 should stretch 300-400%before breaking. As the density of the foam increases, the degree towhich the foam will stretch before breaking increases.

The appropriate thickness of the foam should be determined by theparticular application. The foam must not be so thick as to causeintricate patterns in a design to spring back after removal from themold. On the other hand, a thicker foam layer enhances the hand and airpermeability of the cloth.

C. Film Layer

Film layer 18 may be any elastic, preferably heat-fixable, film whichcan adhere to both foam layer 16 and poured-in-place foam 20. Film 18 ispreferably 0.03-0.7 mm thick and is able to withstand a 400% surfacedeformation. For the invention to work properly, the stretch limits ofelastic composition layer 14 must be approximately equal to or exceedingthe stretch limits of fabric 12.

The film should have a reasonably long life, must resist dry cleaningsolvent, and not be affected by water, humidity or oxidizing agents.

One purpose of film 18 is to guarantee that the cloth is airtight sothat it may be drawn into the mold by a vacuum. Another purpose is toprevent poured-in-place foam 20 from penetrating through fabric 12, thusruining the aesthetic value of the product. Furthermore, the film mustresist the chemical products in the poured-in-place foam.

In the preferred embodiment, film 18 is polyvinyl chloride film. Thisfilm is closed cellular, and is well suited because it is athermoplastic material. However, it hardens when plasticizers in thefilm migrate. Newly developed polymeric plasticizers may be employed toovercome the migration problem. If polyvinyl chloride is utilized asfilm 18, the thickness is preferably 0.1-0.3 mm.

The polyvinyl chloride film of the preferred embodiment has thefollowing composition (% by weight of total):

Vinyl Chloride, 50.0-55.0

Phosphate/phtalate plasticizers, 35.0-40.0

Light and heat stabilizers, 2.0

Epoxy, 0.5

Filler/pigments, 7.5

If polyvinyl chloride is employed as film 18, it is preferable that itbe coated on both sides with polyester-type polyurethane film. FIG. 1illustrates polyvinyl chloride layer 22 coated on both sides withpolyurethane film layers 24 and 26. Film layer 24 is preferably about 20microns thick, while film layer 26 is preferably about 6 microns thick.Polyurethane film layers 24 and 26 permit bonding of polyvinyl chloridelayer 22 to poured-in-place foam 20. Polyurethane coatings 24 and 26also help stop the migration of plasticizers in polyvinyl chloride film22.

Polyester-type polyurethane film may also be employed as film layer 18.This film is highly deformable with a poor memory under heat, because itis thermoplastic. These characteristics are obviously advantageous inthe molding process of the present invention. It appears that athickness of 0.2-0.6 mm is preferred. Another advantage of this film isthat it is water vapor permeable, enhancing the thermal comfort of thefinished product.

The major problem with this film is that pin holes tend to develop fromgas bubbles created during manufacturing. This would permitpoured-in-place foam 20 to penetrate through fabric 12. To avoid thisproblem, the film must be cured very slowly. Otherwise, the bubblesburst during molding to create pin holes.

Rubber may also be employed as film 18. The rubber must be unvulcanizedand may be either natural or synthetic. The same type of rubber productthat is used in bed sheeting is ideal.

The major problem with rubber film is its odor. Anti-oxidizing agentsmust be used. However, care must be exercised in choosing theanti-oxidizing agents since many of the agents commonly used wouldmigrate to the adjacent foam layers over approximately one year anddistort the foam. However, non-migrating oxidizing agents are wellknown. Blocking agents can be placed in the rubber that would break downat a predetermined temperature allowing the rubber to set or vulcanizeduring the molding process. When the rubber is vulcanized during themolding process, the rubber will hold the shape of the mold quite wellafterwards.

Ethylene vinyl acetate copolymer (EVA) may also be employed as film 18.This film is an elastomer and exhibits good stretch and poor memory athigher temperatures. However, EVA is sensitive to high temperatures. Atabout 150° C. it begins to melt and form pin holes. EVA is weak inresisting abrasion. Pin holes form readily from handling. The film maybe made by a rubber calendering system with which large quantities canbe easily produced.

A number of other films may also be used such as neoprene film.

D. Bonding The Layers

The bonding of the various layers within elastic composition layer 14and the bonding of elastic composition layer 14 to fabric 12 must becarefully performed to avoid delamination. Polyvinyl chloride film 22and polyurethane elastomer films 24 and 26 may be applied to foaminterlayer 16 by a transfer or casting process, well known in the art.Specifically, each film is applied as a liquid, the thickness beingcontrolled by a blade. The film is then heated to jellificationtemperature by infra-red lamps. A second controlled thickness is appliedand heated after polyurethane foam 16 is applied, the films pass throughcalender rollers at room temperature, after which the film is bakedunder infra-red lamps. If unvulcanized rubber is employed as film 18, itis passed between calender rollers heated to a temperature less than thevulcanizing temperature.

After film layer 18 is joined to one side of foam layer 16 to formelastic composition layer 14, the opposite side of foam 16 is heated, asin a Reeves machine, and the fabric material is flame-bonded thereto. Itis not preferable to joint both fabric 12 and film 18 to foam 16 byflame-bonding, as this will result in a greater tendency fordelamination of film layer 18.

If foam layer 16 is eliminated, film layer 18 may be glued directly tofabric 12 using, for example, acrylic glue. When film 18 is applied tofoam layer 16, the foam must be relaxed and not under tension.

II. Molding Process

Cloth 10, as described above and illustrated in FIG. 1, is ideallysuited for molding. Cloth 10 is first cut to size and, as illustrated inFIG. 2, preheated to a temperature greater than the temperature at whichfabric layer 12 is heat set and film layer 18 loses its memory. Eitherradiant heat or heated air may be employed. Either radiant heat orheated air may be employed. With polyvinyl chloride as film 18,polyurethane as foam 16 and either wool, polyester or polyamide asfabric 12, a temperature of between 138° C. (280° F.) and 160° C. (320°F.) has been found ideal.

After preheating, hot cloth 10 is inserted in female mold portion 28 asillustrated in FIG. 3. A hollow chamber lies directly beneath the outercontours of mold 28 to which the cloth must conform. Pin holes passthrough the outer contours so that the chamber communicates with theoutside environment. A vacuum is applied to the chamber, thus drawingcloth 10 placed over mold 28 onto the outer contours, as illustrated inFIG. 4. To insure that cloth 10 does perfectly conform to the contoursof mold 28, more pin holes must be located near sharply varying contoursof mold 28 than in the more flat portions of mold 28.

Cloth 10 must be heat set in mold 28 to maximize its ability to retainits shape after the molding process. To this end, mold 28 must be heatedto the heat set temperature when cloth 10 is drawn therein. Atemperature of 149° C.-182° C. (300°-360° F.) has been foundadvantageous in the preferred embodiment. Also mold 28, together withcloth 10, must be allowed to cool so that the temperature of cloth 10drops 17°-27° C. (30°-50° F.) to finish the setting process. After thetemperature of cloth 10 has been raised to 160° C. and then cooled 20°C., the stitch in fabric 12 is set in the shape of mold 28, andtherefore, cloth 10 is less likely to lose its shape after it is removedfrom the mold. Also, since cloth 10 is pressed against the mold wallswhile it is heated, the molding process finishes fabric 12.

Foam 20 may then be poured into mold 28 in its liquid state. In thepreferred embodiment, cold cure, polyether-type polyurethane foam isemployed, although any foam that adheres to film layer 18 may be used.Since a cold cure foam is used in the preferred embodiment, eitherfemale mold 28 must be cooled to a temperature below 38° C. (about 100°F.), or cloth 10 must be transferred to a cool female mold.

Male mold portion 32 is then placed over female portion 28 asillustrated in FIG. 6. After approximately 15 minutes foam 20 has fullyexpanded within the mold. The finished product may then be extractedfrom female mold portion 28 as illustrated in FIG. 7. Thereafter, thecells of poured-in-place foam 20 may be broken by pressure applied byrollers, paddles, or the like. This increases the resiliency of theproduct, prevents shrinkage due to the contraction of gas within thecells upon cooling, and facilitates the circulation of air within a seatto improve the thermal comfort thereof. The result is a finished seatcushion, or the like, as illustrated in FIG. 8.

As indicated above, the ease of molding cloth 10 depends largely on thematerial used as fabric 12 and the intricacy of mold 28. With theprocess described above, relatively inelastic fabrics and complex moldsmay be employed. Specifically, the use of the process of the presentinvention enables cloth to be molded that has never been successfullymolded before. Also, the present invention permits the use of molds ofgreater complexity than has ever been successfully used.

The molding procedure outlined above has been found to produce the bestresults with the widest variety of molds and fabrics. However, if fabric12 has not been subjected, during production, to a temperature highenough to set the stitch of the fabric, many other molding processes maybe employed. For example, the preheating step described above may beeliminated if the mold pattern is relatively simple or an elasticfabric, such as those having a base of texturized polyamide orpolyester, if employed.

Alternatively, cloth 10 may be cut to size, placed in a frame and heatedby air to a temperature of 121°-160° C. (250°-320° F.) while beingpulled down into a female mold by means of a vacuum between the mold andcloth 10. The heat at this time sets the various layers of the cloth tothe contours of the mold. The mold, together with cloth 10, may then beallowed to cool to about 38° C. (100° F.).

Foam 20 may then be poured into the mold in its liquid state. Cold cure,polyether-type polyurethane foam is preferably employed, although anyfoam that adheres to film layer 18 may be used. Since a cold cure foamis used in the preferred embodiment, either female mold 28 must becooled to a temperature below 38° C. (about 100° F.), or cloth 10 mustbe transferred to a cool female mold.

The male mold portion is then placed over the female portion. Afterapproximately fifteen minutes foam 20 will have fully expanded and thefinished product may then be extracted.

Alternatively, cloth 10 may be held to conform to the mold shape by thefoam core or any other method well known in the prior art. The importantpoint is that if the fabric stitch has not been previously heat set, thefabric will be able to stretch sufficiently to conform to even intricatemold patterns.

The following specific examples will serve to illustrate the clothmolding process of this invention. In all examples, fabric 12 was notsubjected, during production, to a temperature high enough to set thestitch of the fabric. Therefore, in all examples, the final heat-fixingof fabric 12 occurs in the mold.

EXAMPLE 1

A moldable cloth was prepared by flame-bonding a double knit polyamidefabric to an elastic composition substrate. The fabric was made oftexturized stretch yarn that had been piece dyed after knitting. Theelastic composition substrate included an open cell polyester-typepolyurethane foam layer which had been cast or laid on a polyvinylchloride film layer. The foam had between 90 and 100 pores per cubicinch, a density of 33 Kg/m³ and a tensile strength of 300% elongationbefore breaking. The thickness of the foam was 3 mm. The film had athickness of 0.3 mm and the following composition (% by weight):

Vinyl chloride, 50.0-55.0

Phosphate/phthalate plasticizers, 35.0-40.0

Light/heat stabilizers, 2.0

Epoxy, 0.5

Fillers/pigments, 7.5

On either side of the polyvinyl chloride layer was a layer ofhydrolytically stable urethane to improve the adhesion between thepoured-in-place polyurethane foam and the polyvinyl chloride. Thethickness of the urethane film between the fabric and the polyvinylchloride was 20 microns, and the thickness of the film between thepolyvinyl chloride and the poured-in-place polyurethane foam was 6microns.

A seat cushion was made, employing this cloth, by first cutting thecloth to the required size, placing it in a frame, and heating it withradiant heat to a temperature of 160° C. (320° F.). While the cloth wasstill hot, it was drawn into the female portion of a mold by means of avacuum between the mold and the cloth. The cloth readily conformed tothe contours of the mold. The mold had been heated to a temperature of171° C. (340° F.). The heat of the cloth in the mold was sufficient toset the stitch of the fabric, and set the film. The mold, together withthe cloth, was permitted to cool 40° F. (22° C.) to set the cloth. Theplacing of the hot cloth in the hot mold, followed by the cooling stepwas sufficient to set the stitch of the fabric, and set the elasticcomposition layer to the shape of the mold.

The cloth was then transferred to a female mold heated to 37° C. (99°F.). A polyether-type polyurethane foam with a density of 52 Kg/m³ wasthen poured-in-place. The male portion of the mold was placed over thefemale portion and the foam was permitted to expand for fifteen minutes.The product was then removed from the mold. Thereafter, the pouredpolyurethane cells were broken by pressure, and the product, a molded,poured-in-place cushion, was complete.

EXAMPLE 2

A moldable cloth was prepared in the same manner as in Example 1 exceptthat the fabric was yarn dyed. The polyurethane foam of the elasticcomposition substrate had a density of 35 Kg/m³ and a thickness of 1.5mm. Also, the thickness of the polyvinyl chloride film was 0.15 mm.

A seat cushion was made employing this cloth by cutting the cloth tosize, placing the cloth in a frame and heating it by radiant heat to atemperature of 149° C. (300° F.). The heated cloth was then drawn intothe female portion of a mold preheated to a temperature of 166° C. (330°F.) under vacuum. The cloth readily conformed to the contours of themold. The mold, together with the cloth, was allowed to cool 17° C. (30°F.). The placing of the hot cloth in the hot mold, followed by thecooling step was sufficient to set the stitch of the fabric, and set theelastic composition layer to the shape of the mold.

The cloth was then transferred to a female mold heated to 38° C. (100°F.). A polyether-type polyurethane foam, with a density of 52 Kg/m³ wasthen poured-in-place. The male portion of the mold was fitted over thefemale portion and the foam was allowed to expand within the mold forfifteen minutes. After removal of the product, the cells of thepoured-in-place polyurethane foam were broken by pressure, and theproduct, a molded, poured-in-place seat cushion was complete.

EXAMPLE 3

A moldable cloth was prepared in the same manner as Example 1 except forthe following differences. A yarn dyed double knit fabric having apolyamide base and a wool face was employed. The density of thepolyurethane foam layer of the elastic composition substrate was 30Kg/m³. The thickness of the polyvinyl chloride film was 0.2 mm.

The procedure of Example 1 was employed to form a seat cushion from thecloth, except for the following differences. The cloth was preheated byradiant heat to a temperature of 157° C. (315° F.). The female portionof the mold had been preheated to a temperature of 160° C. (320° F.).After the cloth was set, it was transferred to a female mold heated to38° C. (100° F.).

EXAMPLE 4

A multiple cloth was prepared in the same manner as Example 1 except forthe following differences. A double knit polyamide and polyestercombination fabric was employed. The density of the polyurethane foamlayer of the elastic composition layer was 40 Kg/m³.

A seat cushion was made, employing this cloth, by first cutting thecloth to the required size, placing it in a frame, and heating it by hotair to a temperature of 132° C. (270° F.), while being pulled down intoand held in a female mold by means of a vacuum between the cloth and themold. The cloth conformed perfectly to the contours of the mold. Theheat at this time set the various layers of the cloth, to the contoursof the mold.

The mold, together with the cloth, was allowed to cool to 32° C. (90°F.). A polyether-type polyurethane foam with a density of 52 Kg/m³ wasthen poured-in-place. The male portion of the mold was placed over thefemale portion and the mold was permitted to expand for fifteen minutes.The product was then removed from the mold. Thereafter, the pouredpolyurethane cells were broken by pressure, and the product, a molded,poured-in-place cushion, was complete.

EXAMPLE 5

A moldable cloth was prepared in a manner similar to Example 3, exceptfor the following differences. A piece dyed, single knit polyamidefabric was employed. The density of the polyurethane foam layer of theelastic composition layer was 35 Kg/m³.

This cloth was utilized to mold a seat cushion in the manner similar tothat of Example 4, except for the following differences. The temperatureof the hot air was 121° C. (250° F.). The mold, together with the cloth,was allowed to cool to 32° C. (90° F.).

Although only a few exemplary embodiments of this invention have beendescribed in detail above, those skilled in the art will readilyappreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. For example, the cloth may be drawn intothe male portion of the mold.

Accordingly, all such modifications are intended to be included withinthe scope of this invention as defined in the following claims.

What is claimed is:
 1. A process for molding cloth comprising the stepsof:drawing the cloth into a mold, the cloth including a fabric layerhaving a heat-fixable fiber, stitches of the fabric having never beenthermally set, and an elastic composition layer bonded to the fabriclayer; and fixing the shape of the cloth to maintain the mold contours.2. A process for molding cloth comprising the steps of:drawing the clothinto a mold, the cloth including a fabric layer having a heat-fixablefiber, stitches of the fabric having never been thermally set, and anelastic composition layer bonded to the fabric layer, the elasticcomposition layer including a film layer; and fixing the shape of thecloth to maintain the mold contours.
 3. A process for molding clothcomprising the steps of:drawing the cloth into a mold, the clothincluding a fabric layer having a heat-fixable fiber, stitches of thefabric having never been thermally set, and an elastic composition layerbonded to the fabric layer, the elastic composition including a flexiblefoam layer and a film layer; and fixing the shape of the cloth tomaintain the mold contours including heating the cloth.
 4. A process asin claim 3 further comprising the step of preheating the cloth prior tothe drawing step.
 5. A process for molding cloth comprising the stepsof:drawing the cloth into a mold, the cloth including a fabric layerhaving a heat-fixable fiber, stitches of the fabric having never beenthermally set, and an elastic composition layer bonded to the fabriclayer; and fixing the shape of the cloth to maintain the mold contours,including heating and cooling the cloth.
 6. A process for molding clothcomprising the steps of:preheating the cloth, the cloth including afabric layer having a heat-fixable fiber, stitches of the fabric havingnever been thermally set, and an elastic composition layer bonded to thefabric layer, the elastic composition layer including a film layer,drawing the cloth into the a mold; and fixing the shape of the cloth tomaintain the mold contours, including heating and cooling the cloth. 7.A process for forming a cloth-covered item comprising the stepsof:drawing the cloth in a mold, the cloth including a fabric layerhaving a heat-fixable fiber, stitches of the fabric having never beenthermally set, and an elastic composition layer bonded to the fabriclayer; and fixing the shape of the cloth to maintain the mold contours,including pouring foam into the mold.
 8. A process as in claim 1, 5 or 6wherein the elastic composition layer has a low elastic recovery aftermolding to facilitate the retention of the molded shape of the cloth. 9.The process as in claim 1, 2, 5 or 7 wherein the elastic compositionlayer includes a flexible foam layer formed from a polymer selected fromthe group consisting of urethane, vinyl chloride, polyvinyl chloride,polychloroprene and rubber.
 10. A process as in claim 1, 5 or 7 whereinthe elastic composition layer comprises:a flexible foam layer bonded tothe fabric layer; and an elastic film bonded to the foam layer.
 11. Theprocess as in claim 10 wherein the flexible foam layer is formed from apolymer selected from the group consisting of urethane, vinyl chloride,polyvinyl chloride, polychloroprene and rubber.
 12. A process as inclaim 1, 5 or 6 wherein the elastic composition layer includes athermoplastic film layer.
 13. A process as in claim 12 wherein the filmlayer is formed from a polymer selected from the group consisting ofvinyl chloride, polyvinyl chloride, polyurethane, synthetic rubber,natural rubber, a mixture of natural and synthetic rubber, neoprenebasis composition, and acrylic acid basis composition.
 14. A process asin claim 1, 5 or 7 further comprising the step of casting a flexiblefoam layer to an elastic film to form the elastic composition layer. 15.A process as in claim 1, 5 or 7 wherein the fabric layer is formed fromthe group consisting of polyamide, polyester, polyvinyl chloride,polyvinyl chloride copolymer, wool, cotton and combinations thereof. 16.A process as in claim 1, 5 or 7 wherein:the process further comprisesthe step of bonding a flexible foam layer to a thermoplastic film layer,and bonding the foam layer to the fabric layer in order to form thecloth.
 17. A process for molding cloth comprising the steps of:bonding aflexible foam layer to a film layer, the foam layer and film layerforming an elastic composition layer; bonding the foam layer to a fabriclayer having a heat-fixable fiber, stitches of the fabric having neverbeen thermally set, the cloth comprising the foam layer, film layer andfabric layer; drawing the cloth into a mold; and fixing the shape of thecloth to maintain the mold contours.
 18. A process as in claim 2, 6 or17 wherein the film layer formed from a polymer is selected from thegroup consisting of vinyl chloride, polyvinyl chloride, polyurethane,synthetic rubber, natural rubber, a mixture of natural and syntheticrubber, neoprene-basis composition, and acrylic acid basis composition.19. A process as in claim 1, 5 or 17 wherein the drawing step includesthe step of creating a vacuum between the cloth and the mold to therebyconform the cloth to the shape of the mold.
 20. A process as in claim 1,3, 5 or 17 wherein the fixing step comprises the step of pouring foaminto the mold.
 21. A process for forming a cloth-covered item comprisingthe steps of:bonding a flexible foam layer to a film layer, the foamlayer and film layer forming an elastic composition layer; bonding thefoam layer to a fabric layer having a heat-fixable fiber, the stitchesof the fabric having never been thermally set, the cloth comprising thefoam layer, the film layer and the fabric layer; preheating the cloth;drawing the cloth into a mold; and fixing the shape of the cloth tomaintain the mold contours, including heating the cloth, cooling thecloth, and pouring foam into the mold.